Method of making trim letters and the like

ABSTRACT

A method for precisely cutting and applying a backing stock such as an adhesive backing to trim objects, in which the backing has substantially the same dimensions as the objects, wherein a sheet of the backing is exposed and positioned, a trim object is positioned on one side of the backing, and a female die having a shape and dimensions which match those of the trim object is positioned on the other side thereof, after which the trim object is pressed into contact with and through the sheet of backing material into the die to thereby sever a portion from the backing material which closely duplicates the shape of the object itself.

[451 Apr. 25, 1972 [54] METHOD OF MAKING TRIM LETTERS AND THE LIKE [72] Inventor: Gerald V. Jakeway, Grand Rapids, Mich.

[731 Assignee: Keeler Brass Company, Grand Rapids,

Mich.

[52] U.S. Cl. ..156/2$0, 83/55 [51] Int. Cl ..B32b 31/18 [58] Field of Search ..156/250, 295, 234, 235, 241,

[56] References Cited UNITED STATES PATENTS 2,772,501 12/1956 Malcolm ..83/542X Pohlenz ..l56/295 X Wales Flint ..l56/251 X Primary Examiner-Benjamin A. Borchelt Assistant Examiner-Daniel A. Bent Attorney-Price, Heneveld, l-luizenga & Cooper ABSTRACT A method for precisely cutting and applying a backing stock such as an adhesive backing to trim objects, in which the backing has substantially the same dimensions as the objects, wherein a sheet of the backing is exposed and positioned, a trim object is positioned on one side of the backing, and a female die having a shape and dimensions which match those of the trim object is positioned on the other side thereof, after which the trim object is pressed into contact with and through the sheet of backing material into the die to thereby sever a portion from the backing material which closely duplicates the shape of the object itself.

7 Claims, 6 Drawing Figures Patented April 25, 1972 0 3 a 4.1 42 4 a a MW U G 2 man H VI a a 7 k "a INVEN'IOR. GERALD V JAKEWAY HMMM BACKGROUND ON THE INVENTION Decorative objects such as trim letters have long been used on manufactured articles such as consumer goods, both for the purpose of decorating the same to provide aesthetic appeal and also for the purpose of affixing trademarks or other such symbolic devices to the goods. For many years, the predominant, if not the exclusive practice, was to use a mechanical connector such as a bolt, screw, rivet, clip or the like to attach the decorative objects. In recent times, however, the availability of new and rather remarkable types of adhesives has made it possible to mount such decorative objects adhesively in a substantially permanent manner.

Mounting the objects by adhesives was a very significant improvement, particularly from the point of view of the amount of material and manufacturing effort involved, as well as the amount and cost of labor in preparation and the like. However, the proper relative positioning and orientation of each individual trim object to be mounted has posed troublesome questions, particularly in high-speed mass production manufacturing and assembly techniques. That is, where bolts, screws and the like were used, the device would have appropriate holes formed in it as a part of its manufacture, and properly locating the trim objects was no problem. Where adhesives are used, however, no such holes or other locating indicia are provided. Still, the trim must be installed at precisely the proper location specified by the designer, of course, and this location must therefore by found by some other means. Also, a need has long existed for some sort of containment apparatus or packaging means by which a plurality of individual different types of trim letters or the like could be shipped, stored, and supplied as a correlated set or unit, in which all of the letters or other such objects required to make up a given word or symbol were provided, preferably in some way which would facilitate the actual mounting thereof.

SUMMARY OF THE INVENTION The present invention provides a novel means of extreme usefulness in the aforementioned areas, wherein a full set of letters or other such trim devices is not only provided as a complete grouping, but is held in containment for safe and efficient shipping, storage and usage, and is further held with each individual such letter or device in its proper position and alignment with respect to the other such letters or objects, so as to actually form the desired word or symbol which is to be attached to a given article of manufacture.

The invention also provides a novel method of cutting and applying a backing to trim objects, the method featuring the use of the trim object itself as a pattern, and as an operative element in the cutting of the stock, basically by exposing a sheet of the backing stock adjacent a female die having dimensions which match those of the object; and using the object itself with the female die to sever a matching portion of the sheet from the remainder of the sheet, by pressing that portion against the object and into the female die and, at the same time, preferably, adhering such portion to the trim object.

BRIEF DESCRIPTION OF THE DRAWINGS In The Drawings:

FIG. 1 is a rear-side elevation of the containment apparatus of the invention;

FIG. 2 is a fragmentary, sectional end elevation taken through the vertical plane II-II of FIG. 1;

FIG. 3 is an enlarged, fragmentary perspective view of a portion of the structure of FIG. I;

Flg. 4 is a fragmentary sectional elevation of an individual trim letter, showing the structural nature thereof;

FIG. 5a is a sectional elevation of a trim letter according to FIG. 4, shown in a stage of its manufacture and illustrating a preferred step in such manufacture; and

FIG. 5b is a sectional elevation similar to FIG. 5a, but showing the completed step.

DESCRIPTION OF THE PREFERRED EMBODIMENT The preferred nature of the present containment apparatus is best seen in FIGS. 1, 2 and 3. Essentially, this embodiment of the apparatus is formed from a section of sheet-like material such as paperboard or cardboard which preferably has a thickness substantially the same as that of the individual trim letters or like objects in connection with which the apparatus is to be used. This sheet of cardboard or the like is folded over along its top to provide a front orforward containment member 12 in which a desired number of recesses 14 are formed. These recesses have a configuration or peripheral shape which corresponds directly to that of the trim letters or other such objects involved in he process, and the recesses extend completely through the thickness of the cardboard forming the member 12. Thus, each such recess 14 actually comprises an aperture passing through the member 12, from one side to the other thereof. Because each such recess is a substantial duplicate of a given individual trim letter, such trim letter will closely fit into the recess, meaning that all or at least some of the periphery of the letter is likely to touch adjacent portions of the periphery of the recess, but not necessarily implying that the trim letter is held in place merely by a frictional engagement alone. Since, as stated, the thickness of the sheet forming the member 12 is substantially the same as that of the individual trim letters, a trim letter positioned within its recess will have its end surfaces in substantially flush alignment with the corresponding side surfaces of the member 12. This is illustrated in FIG. 2, where a trim letter 16 (in this case, the capital letter 0) is fitted into a recess or aperture designated 14a (see FIG. 1 also).

As stated above, the cardboard or other sheet member forming the containment member 12 is folded upon itself along its top extremity. This provides the frontal portion which forms the member 12 mentioned above, and it also provides a rear portion 18 which forms part of a means for retaining trim letters within their respective recesses of apertures; specifically, the flap-like rear portion 18 defines a retainer element which, when folded over, lies juxtaposed to and contiguous with the rearward side of the member 12 (FIG. 2). Thus, the retainer element 18 serves as a closure for one of the otherwise open ends of the various recess apertures 14.

Attached to and extending along the interior surface of the folded-over flap portion 18 is an adhesive strip 20, preferably comprising a layer of pressure-sensitive adhesive which presents a sticky floor at the bottom or innermost end of the various recess apertures; preferably, the adhesive 20 is not merely localized in alignment with each such recess, but extends laterally thereof, behind both the recesses themselves and the interstitial portions of member 12 located between the recesses. In this manner the adhesive will thereby additionally serve to secure the flap-like retainer element 18 to the rear surface of the front member 12.

In either event, the adhesive strip 20 will come into direct contact with and grip the adjacent surface of each of the various trim letters or objects 16, at least when the letters have been fully inserted into their recesses and the respective side surfaces of the letters and of member 12 are in substantially flush alignment. This adhesive engagement between strip 20 and the trim objects will generally be sufficient to securely hold the various letters or other such objects within the containment apparatus, regardless of the various adverse circumstances such as inverted positioning, vibration, etc., to which such apparatus may be subjected in storage and shipping. However, in order to be completely certain that the retention of the trim objects will remain secure at all times, a strip of lightweight, flexible adhesive tape or the like (FIGS. 1, 2 and 3) is applied over the outer side of array of objects 16 and against portions of the outer face of the containment member 12. This strip considerably augments the retention of the objects, since they thus are secured between a pair of spaced adand relative alignment with which they are to be installed or attached to an article of manufacture; i.e., letters such as those illustrated may be arranged and attached or anchored to the containment apparatus r form the particular word (such as a trademark or the like) which they are to spell out when mounted on the article of manufacture of commerce for which they are intended. In a similar manner, letters and design objects may, either by themselves or integrated together, form a desired integrated design device, whose purpose may simply be one of aesthetic value- The term intelligence symbol is used herein to designate any such letter and/or design combination, whether or not it actually spells out a word or symbol of recognized meaning.

Portions of the containment apparatus of the invention are intended for use as indexingmeans, by which the entire apparatus may quickly and easily be oriented upon the article or device to which the decorative letters are to be mounted, to thereby quickly position the letters themselves. Such portions preferably are some of the side edges such as 22 and 24 of the member 12 (FIG. 1). That is, some of the edge extremities of this member may be simply cut along predetermined lines which are directly correlated with the location of the various recesses 14, such that when these edges are placed in direct alignment or registration with certain similar edges (or lines,

' seams or the like) on the article of manufacture, the decorative letters anchored in the various recesses will automatically be properly positioned with respect to the article or device.

In cases where the article or device has an appropriately near or conveniently located corner, and particularly where the article or device comprises a panel such as a trunk lid on an automobile, the indexing edges 22 and 24 of the apparatus may advantageously comprise scams or scored lines by which flaps 23,25 are hinged to the remainder of the member 12. In such a circumstance, the indexing of the apparatus need not be accomplished merely by visibly aligning edge extremities of the respective containment apparatus and article of manufacture, but may instead be done by folding the flaps 23,25 around the corresponding edges of the article of manufacture and'bringing the seams or hinging lines 22 and 24 into flush abutment with the corresponding edges of the panel or the like; As will be appreciated, when two such flaps 23 and 25 are provided, practically no room for error remains, since all the worker must do is pull the aforesaid seams into contact with the corner in the panel or the like, and the angularly' related orientation of the hinging seams will immediately position the letter grouping in each of the two possible dimensions.

Thus, the usage of the present apparatus insofar as its function as a containment and holding device is concerned, and also insofar as its function as an indexing means is concerned, will very readily be appreciated. However, the letters or other such decorative objects or elements themselves preferably have the structure illustrated in FIG. 4, wherein a section 16' of a typical or exemplary such object is illustrated. This structure includes a layer of material 26 forming the actual trim letter or object, preferably a hard and generally rigid material such as a shiny metal, to one side of which is attached, as by a suitable adhesive, a layer of a resilient and yieldable material 28, preferably a rubbery substance which will absorb and dissipate' some shock. Immediately outwardly of the resilient layer 28 is a coating or layer 30 of a suitably strong pressuresensitive adhesive (which may actually be integral with or saturated into the rubbery lever 28), and immediately outward of the adhesive 30 is a relatively thin protective layer 32, of paper or the like, preferably having a slick synthetic facing lying directly in contact with the adhesive, so as to be more readily removable intact therefrom. Such a protective cover or liner is well known in the use of pressure-sensitive adhesives generally, as will readily be appreciated.

Integrated (i.e., mutually attached) adhesive structures including a resilient layer having a pressure-sensitive adhesive on either or both sides, covered by a liner or cover, are presently available in sheet form as a known commercial commodity, and such an integrated adhesive structure is to be preferred for the layers 28, 30 and 32 noted just above.

THE METHOD In accordance with the present invention, the decorative trim letters or other such objects are themselves used as a cutting die to sever their own individual backing of adhesive layers from a sheet of such an integrated adhesive structure or other like backing stock. This is illustrated generally in FIGS. 5a and 5b, where a trim object 16" is shown resting atop a larger sheet of the layered adhesive structure 28,30,32. Immediately beneath the sheet of layered adhesive stock 28,30,32 is positioned a cooperating half (i.e., a female portion) of a die 34 (which may be referred to as a ring) having substantially the same overall configuration as a given one of the various recesses or apertures 14 discussed previously, with a particularly shaped single such die portion for each different letter or decorative symbol, or composite grouping thereof. With the trim object 16" positioned in register over the female die portion 34, pressure (indicated by the downwardly pointed arrows) is applied to the trim object, and it is forced through the integrated sheet of adhesive stock, thereby severing from this stock an individual adhesive element having precisely the same peripheral shape as the trim object itself (FIG. 5b). At the same time, the object may be simultaneously attached to the'cut-out adhesive element, where an adhesive is provided therebetween. It is in the containment apparatus, by insertion into their recess apertures.

In the preferred form just described, the letters or trim objects making up the intelligence symbol to be mounted upon a given device thus have their face or uncoated and unprotected surface placed in contact with the inner adhesive strip 20 of the containment apparatus, whereas the protective liner 32 of the layered adhesive structure is oriented outwardly, generally flush with the outer surface of member 12, with the outer adhesive strip or tape in adhesive contact with both the liner 32 and the said outer surface of the member 12. In this form, all that need be done to permanently mount the intelligence symbol upon a given external device or article of manufacture is to remove the protective liner 32'from the objects, utilize the indexing edges 22,24 and/or flaps 23,35 to properly orient the array of letters or the like, and then bring the pressure-sensitive adhesive layer 30 directly into contact with a surface of such an external device. As soon as this adhesive layer comes into contact with such a surface, adhesion will, of course, commence and the letters or objects will be secured to the extemal'device. It is generally desired to apply some pressure in order to obtain maximum adhesion, however, and in accordance with the present device the presence of the flap-like retainer element 18 provides an eminently suitable mask or cushioning member to which such pressure may be applied, as by a rubber mallet or automated equivalent tool, without actually contacting or damaging the otherwise unprotected outer face of the various trim letters. In this connection, the aforementioned preferred cardboard structural material is well suited for this function, since while it may crush somewhat under pressure of this nature in cushioning the trim letters, it nonetheless will protect the decorative letters from direct contact and possible injury resultant therefrom. Once the pressure has been applied and the letters are in firm adhesion to the external device, the containment apparatus may merely be grasped and pulled away, thereby leaving the decorative letters permanently installed on the external device, in precisely the pattern required to form the desired intelligence symbol.

It is in connection with the removal of the protective liner 32 from the adhesive 30 and resilient layer 28 that the flexible adhesive strip 120 serves its highly useful additional function mentioned previously. That is, this strip may readily be grasped and pulled from the outer face of containment member 12, and when this is done the individual piece of protective liner 32 adhering to the adhesive layer on each individual letter or object will automatically be stripped away from the latter. This exposes the adhesive itself, of course, whereas the pieces of liner 32 remain on the strip 120, which can then merely be discarded. Thus, a single rapid movement or operation is all that is required to plate the array of letters or objects in complete readiness for installation, and an almost equally simple and fast operation will properly orient and locate the entire array upon the external device for attachment thereto, which is itself an exceedingly simple and fast operation. As will be appreciated, mounting of the trim letters in this manner is extremely rapid and accurate, since even though the intelligence symbol forms a relatively large word or design device, it nonetheless may be applied with a minimum of rapidly repetitive strokes or applications of pressure, such that all of the various letters are thereby attached to the external device in a substantially simultaneous manner.

It is entirely conceivable that upon examining the foregoing disclosure, those skilled in the art may devise embodiments of the concept involved which differ somewhat from the embodiment shown and described herein, or may make various changes in structural details to the present embodiment. Consequently, all such changed embodiments or variations in structure as utilize the concepts of the invention and clearly incorporate the spirit thereof are to be considered as within the scope of the claims appended herebelow, unless these claims by their language specifically state otherwise.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.

1. A method of cutting backing stock to a prescribed shape corresponding in dimension to a given trim object, the method comprising the steps of:

a. arranging a portion of the stock in a generally flat position; and

b. using the object itself as a severing instrument by forcing such object into the arranged stock, such that the stock is severed at least in part by edges of such object.

2. A method of cutting backing stock to a prescribed shape corresponding in dimension to a given trim object, the method comprising the steps of:

a. arranging a portion of the stock in a generally flat position, positioning the trim object adjacent a side of the stock, and positioning a die having an edge of substantially the same size and shape as an outline of said object adjacent a side of the stock; and

b. forcing the trim object and die toward one another and severing the stock along said die edge to produce a portion of stock corresponding in shape to said outline.

3. The method as defined in claim 2, wherein said object is forced through said stock and at least partially into said die during said forcing step.

- 4. The method as defined in claim 2, wherein said stock is initially arranged between said object and said die prior to said forcing and severing.

5. Tl-le method as defined in claim 4, wherein said object and die are forced together to sever the stock therebetween.

6. The method as defined in claim 1, including securing the backing stock to the trim object when the stock is severed, by placing an adhesive therebetween prior to forcing the object against the stock.

7. The method as defined in claim 6, wherein said adhesive is carried by said stock and said object is placed in contact with the adhesive and then pressed into the stock as a continuing operation.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3 a 658 619 Dated April 1972 Invcncoflg) Gerald V. Jakeway It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Col. 4, line 18;

' "referred to as a "ring"' should be read as ----referred to as a "blanking ring"---;

Col. 4, line 32;

The sentence "It is in the..." should be read as ---It is in the latter form that the letters or objects are then'anchored to the containment apparatus--- Signed and sealed this 31st day of October 1972.

(SEAL) Attest 2 ROBERT GOT'TSCHALK Commissioner of Patents EDWARD M.FLETCHER, JR. Atte sting Officer 

1. A method of cutting backing stock to a prescribed shape corresponding in dimension to a given trim object, the method comprising the steps of: a. arranging a portion of the stock in a generally flat position; and b. using the object itself as a severing instrument by forcing such object into the arranged stock, such that the stock is severed at least in part by edges of such object.
 2. A method of cutting backing stock to a prescribed shape corresponding in dimension to a given trim object, the method comprising the steps of: a. arranging a portion of the stock in a generally flat position, positioning the trim object adjacent a side of the stock, and positioning a die having an edge of substantially the same size and shape as an outline of said object adjacent a side of the stock; and b. forcing the trim object and die toward one another and severing the stock along said die edge to produce a portion of stock corresponding in shape to said outline.
 3. The method as defined in claim 2, wherein said object is forced through said stock and at least partially into said die during said forcing step.
 4. The method as defined in claim 2, wherein said stock is initially arranged between said object and said die prior to said forcing and severing.
 5. THe method as defined in claim 4, wherein said object and die are forced together to sever the stock therebetween.
 6. The method as defined in claim 1, including securing the backing stock to the trim object when the stock is severed, by placing an adhesive therebetween prior to forcing the object against the stock.
 7. The method as defined in claim 6, wherein said adhesive is carried by said stock and said object is placed in contact with the adhesive and then pressed into the stock as a continuing operation. 